News

UNB Launches Marine Additive Manufacturing Centre of Excellence

On Tuesday the University of New Brunswick launched Canada’s first research centre for 3D metal printing for the marine and defence industries.

Dr. Mohsen Mohammadi, director of the Marine Additive Manufacturing Centre of Excellence and master’s student Carter Baxter examine a 3D printed metal component. Image: Rob Blanchard Photo UNB

The  Marine Additive Manufacturing Centre of Excellence  will combine research, commercialization and workforce development and training.  This centre is the result of a partnership between the University of New Brunswick, Custom Fabricators and Machinists (CFM), and community colleges in New Brunswick and Nova Scotia.

The centre will be the first in Canada to use 3D metal printing for manufacturing certified, custom parts for the marine sector. Its mission is to ensure the adoption of this technology in the marine sector by developing new methods, procedures, and effective training programs.

Dr. Mohsen Mohammadi, director of the Marine Additive Manufacturing Centre of Excellence and assistant professor of mechanical engineering at UNB, will lead the research and development component of the centre, with CFM partnering on commercialization. The New Brunswick Community College, Collège Communautaire du Nouveau-Brunswick and the Nova Scotia Community College will lead workforce development and training.

“We’re seeing more and more people show interest in coming to New Brunswick to be part of what we’re doing.  This is the first centre of its kind in Canada and we are doing it right here in New Brunswick,” said Mohammadi. “Our technology is greener and more efficient than conventional methods and will create high value jobs here in Atlantic Canada.”

The multi-million-dollar centre is currently funded by Lockheed Martin Aeronautics and Irving Shipbuilding Inc. Lockheed Martin Aeronautics’ $2.7-million contribution is a part of its industrial and regional benefits obligation to the federal government for its contract for the CP-140 Aurora Structural Life Extension Project.

“We are very pleased to see our Industrial Technology Benefit supporting the creation of the University of New Brunswick’s Marine Additive Manufacturing Centre of Excellence. Innovations such as 3D metal printing are the way of the future and Lockheed Martin is always looking at methods to increase our efficiency and effectiveness in the field of advanced manufacturing,” said Charles Bouchard, CEO of Lockheed Martin Canada, in a release.

Irving Shipbuilding’s $750,000 investment is a part of its Value Proposition commitments under the National Shipbuilding Strategy (NSS).

“As the commercialization partner, CFM is pleased to be hosting the 3D printing equipment at our facility, and we look forward to working with the community colleges to provide a hands-on classroom to train the next generation of skilled machinists and fabricators,” said David Saucy, vice-president construction and equipment division of J.D. Irving, Limited, in a release.

“We also look forward to working closely with Dr. Mohammadi and his team as we integrate this new technology into our existing global customer base as well as developing new markets in the growing marine manufacturing sector.”

The university says nearly $5-million centre is expected to triple its funding in the coming year with other partners coming on board.

Government of Canada announces $8.9 million AM investment in the University of Waterloo

May 24, 2017 (Waterloo, Ontario) – The Honourable Bardish Chagger, Leader of the Government in the House of Commons and Minister of Small Business and Tourism, announced an $8.9 million investment in the University of Waterloo’s Multi-Scale Additive Manufacturing (AM) Lab. This investment will establish Canada’s first major advanced manufacturing technology commercialization centre.

“This project will support up to 18 new partnerships, help commercialize up to 21 advanced manufacturing technologies and create over 80 jobs,” said Minister Chagger. “It will also provide opportunities for students from the University to prepare for the manufacturing jobs of tomorrow.”

“Innovation and skills development are the driving forces behind manufacturing, trade and a better future for middle-class Canadians. Harnessing innovative technologies is crucial to the future of Canada’s manufacturing sector,” said Dennis Darby, President and CEO of Canadian Manufacturers & Exporters (CME). “Today’s announcement is a clear example of strong, coordinated government action CME has been calling for to reinvigorate the manufacturing sector to match global competition.”

“Canada Makes is very pleased with the Government of Canada’s investment. It recognizes the importance of additive manufacturing to the future of Canada’s economy, said Martin Lavoie, Executive Director Canada Makes. “This most certainly will help grow Canada’s global competitiveness by making it easier for manufacturers to adopt additive metal manufacturing processes.”

A broad range of industrial partners including aerospace, mining and automotive, will work with the University of Waterloo’s Multi-Scale AM Lab’s state-of-the-art technology and develop innovative 3D printing solutions to streamline manufacturing in Canada.

Canada Makes will continue working closely with the team at the University of Waterloo in helping Canadian industry to adopt AM to their process and keeping Canada a world leader in innovative technology.

About the Canadian Manufacturers & Exporters:
Since 1871, Canadian Manufacturers & Exporters has been helping manufacturers grow at home and thrive around the world. In 2016, CME released Industrie 2030 – a roadmap for doubling Canadian manufacturing activity by 2030. Our focus is to ensure the sector is dynamic, profitable, productive, innovative and growing. We aim to do this by strengthening the labour force, accelerating the adoption of advanced technology, supporting product commercialization, expanding marketplaces and, most importantly, ensuring a globally-competitive business environment. CME is a member-driven association that directly represents more than 2,500 leading companies who account for an estimated 82 per cent of manufacturing output and 90 per cent of Canada’s exports. www.cme-mec.ca

About Canada Makes
A Canadian Manufacturers & Exporters (CME) initiative, Canada Makes is a network of private, public, academic, and non-profit entities dedicated to promoting the adoption and development of additive manufacturing in Canada. For more information on Canada Makes, please visit www.canadamakes.ca

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Design for additive manufacturing: Guidelines & case studies for metal AM

The Government of Canada recently commissioned the Fraunhofer Institute to deliver a report ‘Design for Additive Manufacturing (AM) – Guidelines and Case Studies for Metal AM’. The goal of the report is the help Canadian companies and researchers take advantage of existing knowledge in metal AM.

The report is based on seven components each tailored to the specific needs of the chosen AM technology. It identifies leading edge industrial applications and trends associated with the design for AM and limitations related to current AM technologies. The evaluation of the seven case studies highlights general design principles to take best advantage of the powder bed based additive manufacturing techniques Laser Beam Melting (LBM) and Electron Beam Melting (EBM).

1. Bionic Wheel Carrier of Electric Vehicle – Automotive / Motorsports

2. Main Gearbox Bracket – Aerospace

3. Calibration Tool for Extrusion Process –  Energy

4. Heat Exchanger – Energy

5. Miniature Heat Exchanger / Cooler – Not limited to specific industry

6. Functionally integrated Implant – Medical

7. Functionally integrated Tooling Segment – Tooling

Compared to conventional manufacturing methods additive manufacturing technologies provide unique opportunities and freedom in design, resulting in a high degree of product individualisation. Building parts layer by layer without using any tooling, moulds or dies enables the design and manufacturing of very complex component geometry, such as lattice structures or free formed surfaces and organic shapes.

Hinge assembly manufactured in one shot with LBM (Source: Fraunhofer IWU)

Design attributes like undercuts are no longer a limitation and with the aid of topology optimisation the component geometry can be tailored to the specific needs of application. In addition to it, features and functionalities can be incorporated into a part just during the manufacturing process in one shot and assemblies consisting of many components can be reduced to a single part. Even the assembling of different parts during primary shaping with AM technologies is possible, which has already been demonstrated for components like bearings, chains, hinges.

Moreover, the design optimisation and material characterisation are analysed. Finally, there are given overall conclusions with focus on AM-specific design optimisation, main flaws and weaknesses of the considered metal AM processes as well as aspects of AM commercialisation.

Example for topology optimisation – skateboard axle mounting, manufactured with LBM (Source: Fraunhofer IWU)

Skateboard Truck (Titanium) , LBM design demonstrator with topology optimisation and graded lattice structures (Source: Philipp Manger)

This is a small sample of what is available in this comprehensive report. We invite you to download this report and take full advantage of the know-how on offer.

Download the full report here.

Redesigning medical instruments using 3D metal printing

3D metal printing helps surgeons to perform heart operation

Additive manufacturing methods of 3D printing are increasingly opening up new paths in medical technology. Alex Berry, founder of Sutrue (UK), and Richard Trimlett, consultant at the Royal Brompton Hospital, are focusing strategically on AM for applications in cardiology. Is it possible to improve the “golden hands” of an experienced heart surgeon? Yes, it is. Using the example of a machine for performing sutures during operations and a cardiac stabilizer for endoscopic heart operations, Sutrue shows how operations on the heart can be performed more safely. Heart operations are soon to become faster and safer. And there is even more good news: patients are recovering faster.

Sutures following operations are still stitched up today in almost the same way as they were in the days of the ancient Egyptians. Alex Berry discovered that around 240,000 medical professionals a year globally suffer needlestick injuries as a direct consequence of this stitching. Even experienced operators are confronted with the drawbacks and inaccuracies of previous suturing methods. To change this trend, Sutrue developed an instrument which automatically passes any curved needle with a suture through the tissue of a patient. The requirements placed on the automated suturing device were that the stitches are made quickly, are positioned precisely, are reproducible and are made with the necessary force. The better and more quickly the suturing can be performed, the shorter the operation is for the patient as well. And a clean stitch also leads to better recovery.

The perfect mechanics of an automated instrument: Suture quickly, reproducibly and cleanly in a heart operation

View of the opened gear mechanism for driving the rotating needle of the automated suturing device – the gear teeth are just 0.4 mm long

The extremely slender suturing device is inserted via a conventional endoscope the size of a drinking straw during the heart operation and moved into position. Its head can rotate and be pivoted in order to find any desired batch of tissue. The needle rotates softly and with pinpoint precision during suturing. This is possible thanks to a complex miniature gear mechanism that drives the needle. The entire gear mechanism is an AM assembly. What this innovation actually means for the operator is that the suture is pulled through quickly and cleanly and the stitch is automatically set in place. A few small stitches in arteries or in delicate structures are now possible. Each stitch can be performed with reproducible accuracy using the suturing device. Complicated operations in particular can be performed faster and more safely. Thanks to the suture device, up to three rotations of a needle per second are now possible, instead of one stich per 25 seconds while doing by hand. This reduces the risk associated with the operation for both, patients and surgeons.

Idea of stabilizing the heart muscle during the operation
In Great Britain alone, around half a million people live with a heart defect. Treatment with drugs only delivers very minor improvements to patients and often an operation on the heart is the only way to save a person’s life. In Great Britain, cardiovascular disease is the second most common cause of death, accounting for 27% of deaths, after cancer, which accounts for 29% of all deaths. During open-heart surgery, the surgeon needs the heart muscle to be stabilized for an intervention to be made. Richard Trimlett outlines the task: “We’re doing a beating heart operation so the heart is in use by the body but we need to hold the small area that we’re working on still. With the chest open we can put a big suction device in but when we’re doing keyhole surgery we need very small parts that we can pass in and out. What we don’t want to do is disadvantage the patient by offering them an inferior stability of the heart so that the quality of the operation isn’t as good when you do it as a keyhole. I said to Alex, ‘could you make something that comes apart in pieces, pass through a very small incision that we can use to hold the heart stable? Could we make it to throw it away and even customise it to the different shapes and sizes?’” For Richard Trimlett it was clear that the heart stabilizer should be small, be capable of being dismantled, and be designed with exposed channels pre-assembly. The role of the stabilizer is to keep the heart muscle still at the precise point where the surgeon wants to make an intervention. Alex Berry took on the task and presented a biocompatible prototype of the heart stabilizer: one part made of plastic (SLS) and one part made of metal (LaserCUSING). The component consists of a rod on which the U-shaped heart stabilizer is inserted, like a stamp. The surgeon presses the stabilizer onto the operating site that he wants to keep still to make an intervention. 

Short development time and care for the patient
The heart stabilizer was successfully developed in just three months. Previously, it was not uncommon for such a new development to take up to ten years. The component itself is printed by ES Technology on an Mlab cusing from Concept Laser  in the space of three to four hours. It consists of a metallic basic body and several plastic suction points that aspirate by means of a vacuum. Both parts are joined together using a sandwich technique. “The solution is estimated to have cost only around £15,000 to develop. Comparable conventional developments used to cost upwards of a million pounds,” says Berry to illustrate the relative sums involved. But from Richard Trimlett’s point of view, it is primarily the patient who benefits from the new instruments using in heart operations. Here he cites an average rehabilitation time for the patient of around six months following a conventional surgical intervention. “Initial experience indicates,” according to Richard Trimlett, “that patients undergo a demonstrably gentler procedure and can recover after just three to four weeks.”

Cooperation between surgeons and Sutrue
The Sutrue Team have been involved in the development of medical operating equipment for more than 10 years. A precise analysis of the operating method is absolutely essential to allow suitable medical instruments to be developed. To achieve this, surgeons work together closely with expert medical consultants, such as Richard Trimlett. Trimlett, who is a cardiologist, attempts to translate the specifications and wishes into a specific set of requirements. With Alex Berry from Sutrue, he has access to a manufacturing expert who transfers the requirements into CAD designs and geometries. Sutrue has been working with AM methods for around (ten) 7 years. “AM makes it possible to produce geometries that cannot be achieved using traditional manufacturing methods. In addition, the parts have greater performance capacity or functional precision, or else they are extremely delicate or small. This is often precisely what the surgeon was previously lacking,” explained Alex Berry. 

Sutrue relies on machine technology from Concept Laser
ES Technology, Concept Laser’s UK distributor, manufactures the parts for the automated suturing device on an Mlab cusing machine using the LaserCUSING process, also known as 3D metal printing. The Mlab cusing is particularly suitable for manufacturing delicate parts where a high level of surface quality is demanded. The special thing about the compact machine is its very user-friendly, pull-out drawer system that is very safe at the same time. This includes both the build chamber with dose chamber and the storage container. It allows a rapid change of material without the risk of any contamination of powder materials. The patented drawer system is available with three different sizes of build envelope (50 x 50 x 80 mm3, 70 x 70 x 80 mm3, 90 x 90 x 80 mm3). Also available now is its “big brother,” the Mlab cusing 200R, which allows even greater productivity thanks to a doubling of the laser power from 100 watts to 200 watts. In addition, a larger build envelope has been created and this increases the build volume by as much as 54% (max. 100 x 100 x 100 mm3).

In this case, the machine technology from Concept Laser makes it possible to produce the teeth of the gear mechanism, which are just 0.4 mm long. Up to 600 parts can be printed on one single build plate. After the tooth system has been removed from the powder bed, it does not require any finishing thanks to the very high accuracy of the metal-powder-based process. Stainless steel 316L is used. Alex Berry explains: “In addition to the restrictions on geometry, conventionally milled or cast parts have a few other drawbacks. It takes a great deal of time to get to the finished prototype. In addition, the costs are very high. In 3D printing the parts are produced very quickly and at a fraction of the previous costs of prototyping. But the potential for bionic designs, reproducibility, miniaturization and not least the reduction in the number of parts and outlay on assembly is also vast. If one looks at the full spectrum of optimizing manufacturing and product design coupled with an increase in functionality, 3D printing is capable of revolutionizing medical instruments.”

automated suturing device on the build plate

Additively manufactured parts of the automated suturing device on the build plate of an Mlab cusing from Concept Laser

Outlook
Richard Trimlett and Alex Berry already see an even greater challenge on the horizon. The buzzword is artificial hearts, that is to say mechanical pumps that perform the function of the heart. The previous models have weaknesses. AM could lead to new thinking in this area. The pump could be designed to be smaller. The really intriguing thing, according to Richard Trimlett, is the possibility of integrating electromagnetic functions for moving the pump. These are just a few of the basic considerations for redesigning mechanical heart pumps. AM seems to be inspiring the experts in the field of cardiology.

State-of-the-art equipment for innovative AM research at McGill University

Renishaw AM400

Renishaw AM400

McGill University is very excited about its recent acquisition of new equipment that greatly increases its additive manufacturing (AM) capabilities. Located in Prof. Mathieu Brochu’s laboratory at McGill in Montreal are now two new Renishaw laser powder bed units, an AM250 and an AM400.

“These units will be used to expand the boundaries of AM, particularly in the critical areas of processing of materials sensitive to cracking, microstructure control, and the relationship of the former to powder quality and chemical composition,” said Prof. Brochu. “Tapping into McGill’s existing expertise in pulse-based AM processing, the primary objective will be to open new AM opportunities for industry by providing new and higher performance AM alloys/parts.”

Moreover, installed in January and complementing the new 3D printing capability available is a new ZEISS Xradia 520 Versa 3D X-ray nano-CT scanner. McGill researchers and other institutions now have access to this powerful CT scanner. This technology has the capability to detect defects with a 700 nm special resolution with a minimum 70 nm voxel size, and is instrumental in helping to minimize defects using AM.

 

ZEISS Xradia 520

ZEISS Xradia 520

The Xradia 520 Versa is capable of non-destructive 3D submicron imaging. It can analyze a wide variety of solid and soft materials including rock, metal, polymers, glass as well as biological hard and soft materials such as stained or unstained tissue.

Canadore introduces additive manufacturing capabilities to companies building parts for space mining

Canadore College’s Innovation Centre for Advanced Manufacturing and Production (ICAMP) and Canada Makes are helping ensure Canada’s participation in the next stages of mining in space. Working with Ontario based Deltion Innovations and Atlas Copco, ICAMP introduced its additive manufacturing capability to produce prototype tool ends for a space mining multi-purpose tool, labeled PROMPT (Percussive and Rotary Multi-Purpose Tool). The device would prospect for water, ice and resources on the moon and beyond.

“For obvious reasons, this project was a dream to work on,” said Evan Butler-Jones, applied research lead at ICAMP. “The complexity of this undertaking made it both challenging and exciting. It is thrilling to participate in this small way to Canada’s efforts in developing the space mining industry.”

Canada Makes helped fund the eight-month project through its Metal Additive Demonstration Program. Butler-Jones had this to add, “Canada Makes funding was essential in proving the potential of additive for these tools, and led to further work completing the final parts. The final parts were a hybrid of additive with post machining of certain features.‎”

Deltion describes the combination drill and rotary multi-use tool as a “space-age Swiss Army knife.” One of the goals is to be able to drill mine for water and ice on the moon. It would also be used in robotic construction, maintenance and repair tasks.

Atlas and Deltion brought the PROMPT concept and tool designs to ICAMP for manufacturing and production. The Centre utilized its additive manufacturing resources, including its 3D metal printer the EOS M290 and computer numerical control equipment, to prototype the commissioned parts.

Canadians to develop space mining tool

Artist rendition of a mining operation in space. (Screenshot via YouTube)

“Deltion has been working on space mining technologies for almost two decades,” said Dale Boucher, CEO of Deltion Innovations. “The use of additive manufacturing is a means to develop the complex geometries required for the tool ends of PROMPT. We are very pleased with the results of this project and we look forward to a continued collaboration with ICAMP.”

The finalized products were delivered to Deltion Innovations, who will be testing the multi-purpose tool for future deep space applications with an eye on the moon, the asteroids and even Mars.

About Deltion Innovations
Deltion Innovations Ltd. is an award winning mining equipment Design Company.  The highly skilled team of professionals has been designing and fabricating drilling and excavation technology for more than a decade, specializing in transferring and adapting technologies developed in the space sector to the terrestrial market and vice versa. www.deltion.ca

About ICAMP
Canadore College’s Innovation Centre for Advanced Manufacturing and Production (ICAMP) consists of 13, 300 sq. ft. of industrial lab and design space capable of helping small- and medium-sized enterprises conceptualize, design, prototype, test and manufacture products. The Centre includes a large boardroom and 12-seat 3D theatre and specializes in additive manufacturing, precision 3D scanning, design and simulation software, CNC manufacturing, robotics, microscopy, destructive material testing, and non-destructive material testing. Resources include EOS and Stratasys equipment, Creaform scanning equipment, 3DS Solidworks, Solidthinking Inspire and Geomagics, 9-axis machining centre, waterjet cutting, YuMi robot, scanning electron microscope, multiple optical microscopes and more www.canadorecollege.ca

About Canada Makes
A Canadian Manufacturers & Exporters (CME) initiative, Canada Makes is a network of private, public, academic, and non-profit entities dedicated to promoting the adoption and development of additive manufacturing in Canada. For more information on Canada Makes, please visit www.canadamakes.ca or contact Frank Defalco at frank.defalco@cme-mec.ca

The Metal Additive Manufacturing Demonstration Program is funding by NRC-IRAP and is designed to help Canadian industries increase awareness and assist in understanding the advantages of the metal additive manufacturing (AM) technology. Canada Makes works with a group of AM experts who provide participating companies guidance of the advantages and business opportunities in terms of cost savings and efficiencies of AM.

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Precision ADM, Melet Plastics & Canada Makes partner on conformal cooling project

Precision ADM recently completed a conformal cooling mold project that developed an improved “Venturi Cup” for Melet Plastics. The project received funded from Canada Makes through its Metal Additive Demonstration Program. The goal of the project was to show how a mold optimized using additive manufacturing (AM) methods can increase quality and productivity.

AM conformal cooling mold design

AM conformal cooling mold design. CAD models supplied by Melet Plastic Inc.

“This project is an excellent example of how the Metal Additive Demonstration Program works,” said Frank Defalco Manager Canada Makes. “Learning about the capabilities offered by adopting AM is what will make Canadian industry more productive and conformal cooling is a key area that needs to be exploited.”

One of the major factors contributing to the deformation of molded plastic parts is a lack of uniform heat distribution throughout molds. Various areas of the final part created by a mold cool at different rates creating internal stresses and deformations.

Dale Kellington General Manager of Precision ADM  stated, “conformal cooling applications continue to  have a direct impact on part quality, cycle times and productivity of injection molded parts”

A warping defect was reported in the production of a “Venturi Cup” part manufactured by Melet Plastics Inc. for use in an AGCO-Amity JV air seeder. The goal was a reduction in the warping seen in the large rectangular section of the part. Proposed alterations included changes in material, wall thickness and coolant temperature, as well as an optimized mold for cooling produced by Precision ADM using additive manufacturing methods.

Molded part new - old

Using conventional mold design, coolant channels are required to be drilled as a separate operation but are restricted to a path of connecting straight lines. This restriction is the cause of non-uniform heat distribution that causes part deformation. Additive manufacturing methods can be used to create molds featuring a coolant channels that follow the contours of a mold, drastically improving heat distribution during cooling. This has the added benefit of eliminating the task of drilling cooling channels.

Dale added, “with software such as Moldex our engineers can simulate the injection molding process and demonstrate the beneficial cooling characteristics of conformal cooling molds for production”

Mold - Tradition design versus conformal cooling AM designed

Mold – Tradition designed mold versus conformal cooling AM designed mold. CAD models supplied by Melet Plastic Inc.

The project showed significant results. This application of additive manufacturing showcases the complex subsurface geometries that are possible using the method. The use of the optimized mold together with a decrease in wall thickness resulted in a warpage reduction of 42%; an overall warpage reduction of 54% was achieved with all other alterations included.

About Precision ADM
Precision ADM is a contract engineering and manufacturing solutions provider that uses additive manufacturing (3D Printing) as a core technology. Precision ADM has created a full Advanced Digital Manufacturing hub from Design to Engineering, to Manufacturing and finishing.  Complimented by multi-axis machining capability, PADM identifies, develops, and manufactures high value components and device applications for the medical, aerospace, energy and industrial sectors. PADM is headquartered in Winnipeg, Manitoba, Canada. www.precisionadm.com

About Melet Plastics Inc.
As Leaders in Engineering Plastics Solutions, the Melet team is dedicated to engineering custom plastic products that meet the needs of Original Equipment Manufacturers. Melet offers a comprehensive array of services to ensure that every step of the development process is a success – from product design, engineering, material selection, and rapid prototyping, to mold manufacturing, injection molding, and assembly. Melet operates out of a state-of-the-art manufacturing facility complete with extensive automation and robotics. New capabilities include compression thermoforming of natural fiber composites at the Fargo location. www.meletplastics.com

About Canada Makes
A Canadian Manufacturers & Exporters (CME) initiative, Canada Makes is a network of private, public, academic, and non-profit entities dedicated to promoting the adoption and development of additive manufacturing in Canada. For more information on Canada Makes, please visit www.canadamakes.ca or contact Frank Defalco at frank.defalco@cme-mec.ca

The Metal Additive Manufacturing Demonstration Program is funding by NRC-IRAP and is designed to help Canadian industries increase awareness and assist in understanding the advantages of the metal additive manufacturing (AM) technology. Canada Makes works with a group of AM experts who provide participating companies guidance of the advantages and business opportunities in terms of cost savings and efficiencies of AM.

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McMaster University joins Canada Makes

Canada Makes is pleased to welcome McMaster UniversityMcMaster University as a member to its network. A world-class institution, McMaster’s Faculty of Engineering plays a key role in helping the University earn its well-deserved reputation as one of Canada’s most innovative universities in learning and research.

“McMaster’s is delighted to be part of Canada Makes and play an important role in moving up the bar for Canada’s additive manufacturing (AM) sector,” said Prof. Mohamed Elbestawi, Director W. Booth School of Engineering Practice and Technology, which is part of McMaster University’s Faculty of Engineering. “We share Canada Makes’ vision of getting more people involved in and helping industry in adopting AM.”

Canada Makes is looking forward to working with McMaster University to further our common goals. Partnerships like this, developed through Canada Makes, only improve Canada’s AM eco-system, creating an environment where the sector can thrive,” said Frank Defalco, Manager Canada Makes.

About McMaster University
Founded in 1887, McMaster University is one of only four Canadian universities consistently ranked in the Top 100 in the world.

The McMaster Faculty of Engineering has a reputation for innovative programs, cutting-edge research, leading faculty, and aspiring students. It has earned a strong reputation as a centre for academic excellence and innovation. The Faculty has approximately 160 faculty members, along with close to 4,000 undergraduate and about 1000 graduate students. www.mcmaster.ca

About Canada Makes
A Canadian Manufacturers & Exporters (CME) initiative, Canada Makes is a network of private, public, academic, and non-profit entities dedicated to promoting the adoption and development of additive manufacturing in Canada. For more information on Canada Makes, please visit www.canadamakes.ca or contact Frank Defalco at frank.defalco@cme-mec.ca

Canada Makes, Edmit & MDA team up for innovative space application parts

Canada Makes, Edmit Industries Inc. of Chateauguay Quebec and MacDonald, Dettwiler and Associates Ltd. (MDA) of Ste-Anne-de-Bellevue Quebec partnered to build 3D printed Titanium parts for an innovative graphite strut structure for flight application. This is another Additive Manufacturing (AM) project that demonstrates how this technology offers solutions not straightforwardly feasible through conventional manufacturing means. Canada Makes enabled, with funding through its Metal Additive Demonstration program, the manufacturing development and build of the Titanium 3D printed parts at Edmit.

“This is yet another example of how additive manufacturing is transforming how satellite parts are being manufactured” says Joanna Boshouwers, MDA’s Vice President and General Manager. “The parts were 3D printed by Edmit, and then tested by MDA to the extreme temperatures of space and the punishing vibration environment of a launch. The Canada Makes program played a key role in accelerating the adoption of AM for this space application, which will lead increase use of this AM technology going forward.”

“One of the primary goals of the Canada Makes program is to promote the Canadian additive manufacturing industry, and this successful project will go a long way to encourage increased use of this technology,” said Frank Defalco, Manager Canada Makes. “Additive manufacturing is a disruptive technology, and this project is testimony of that fact, and we are excited about the opportunities this solution provides to other companies.”

MDA-Edmit-2

3D Printed Titanium Bracket and Hub for a Satellite Graphite Strut Structure

The parts are used in the assembly of a lightweight antenna graphite spaceframe, optimized for strength, stiffness, thermal performance and mass.

Various satellite manufacturers are using additive manufacturing to reduce cost and schedule required to build spacecraft parts. Space System Loral (SSL), a subsidiary of MDA, recently announced they also started to incorporate the technology into their satellite structures.

Although 3D printing offers new possibilities in the manufacture of satellites, the transition from conventional manufacturing to this new AM approach can be somewhat challenging and expensive. It is therefore important to adopt this technology in the appropriate circumstances in order to get the full benefit.

The Metal Additive Manufacturing Demonstration Program is delivered by Canada Makes through funding by NRC-IRAP. The program is designed to help Canadian industries increase awareness and assist in understanding the advantages of the metal additive manufacturing (AM) technology. Canada Makes works with a group of AM experts who provide participating companies guidance of the advantages and business opportunities in terms of cost savings and efficiencies of AM.

About MDA
MDA is a global communications and information company providing operational solutions to commercial and government organizations worldwide.

MDA’s business is focused on markets and customers with strong repeat business potential, primarily in the Communications sector and the Surveillance and Intelligence sector. In addition, the Company conducts a significant amount of advanced technology development.

MDA’s established global customer base is served by more than 4,800 employees operating from 15 locations in the United States, Canada, and internationally. www.mdacorporation.com

About Edmit
A small to medium size company that specializes in the manufacturing of high-end precision components and assemblies. As Innovators and researchers, EDMIT provides leading edge and innovative methods and concepts. With more than 35 years of expertise, Edmit Inc. specializes in metal additive manufacturing (3D printing) of precision metal parts for the aerospace, space and medical industries and have been a key partner for research and development projects for space application for the past five years. edmitinc.com

About Canada Makes
A Canadian Manufacturers & Exporters (CME) initiative, Canada Makes is a network of private, public, academic, and non-profit entities dedicated to promoting the adoption and development of additive manufacturing in Canada. For more information on Canada Makes, please visit www.canadamakes.ca or contact Frank Defalco at frank.defalco@cme-mec.ca

 

P&G and AMM partner with Canada Makes’ Metal Additive Demonstration Program

Procter & Gamble Belleville Plant partnered with Additive Metal Manufacturing Inc. (AMM) and Canada Makes to explore building new customized parts using additive manufacturing (AM). The project was funded through Canada Makes’ Metal Additive Demonstration Program.

“Parts can be very difficult even impossible to make with traditional subtractive machining processes,” said Haixia Jin, FullSizeRenderP&G Engineering Technical Manager. “Metal 3D printing offers an exciting alternative to commercial off-the-shelf parts that cannot achieve complicated design requirements or internal cavity geometry. Even in cases where commercial customization is available and able, it usually comes with significant additional cost or an unbearable long lead-time.”

The example piece of work is printed to serve the combined purposes to deliver fluid to designated locations with the four extended legs while minimizing disturbance to the flow that it merges in. The vast metallurgy choices also provide a wide spectrum of chemical/environmental resistance. This illustrated part was printed in Stainless Steel taking advantage of its good anti-corrosion performance.

“AMM is delighted to be partnering with P&G and Canada Makes in assisting P&G introduce 3D METAL printing into their supply chain,” said Norman Holesh, President AMM. “P&G embarked on this journey with the full understanding that to be successful, the technology must be embraced as early as possible in the design stage. This technology is neither an alternative to subtractive manufacturing nor a replacement for it but an addition to the entire manufacturing process and allows for previously unthinkable designs and a dramatic reduction in lead times.”

IMG_6928“Design rules have changed and AMM works with its customers to help them understand and embrace these changes and take full advantage of design freedom,” added Holesh

“Designing and building complex parts as well as the lead-time saved are two big advantages that AM offers users of the technology. This project certainly was an excellent example offered through Canada Makes’ Metal Additive Demonstration Program,” stated Frank Defalco Manager Canada Makes. “Canada Makes will continue to partner with Canadian companies looking to the advantages offered by having additive manufacturing as a powerful new option in creating parts previously unfeasible.”

About AMM

Advanced Manufacturing Canada
Additive Metal Manufacturing Inc. is a full-service 3D METAL printing bureau located in Toronto and assists its customers understand the additive journey from design all the way to finished printed component parts. AMM is a progressive, productive and respected leader providing integrated and advanced manufacturing technology solutions within the emerging market for AM ensuring their industrial partners have the best opportunity to excel and Take Back Manufacturing for Canada. AMM is certified with both ISO 9001 and for Controlled Goods. www.additivemet.com

About Procter & Gamble Belleville Plant
Opened in 1975, the Belleville, Ontario site now produces Always and Olay products for North America and the globe.

  • In 1984, the Belleville site started manufacturing Always feminine care products
  • The site currently manufactures the entire line of Always products, including pads, liners, Always Infinity and Always Discreet, as well as Olay Daily Facials
  • Since 2010, the site has received a prestigious manufacturing excellence award, the highest recognition among P&G manufacturing facilities

To celebrate their 40th anniversary, the site set a Guinness World Record for the largest game of “Follow the Leader” in the world.

The Metal Additive Manufacturing Demonstration Program is funded by NRC-IRAP and is designed to help Canadian industries increase awareness and assist in understanding the advantages of the metal additive manufacturing (AM) technology. Canada Makes works with a group of AM experts who provide participating companies guidance of the advantages and business opportunities in terms of cost savings and efficiencies of AM.

About Canada Makes
A Canadian Manufacturers & Exporters (CME) initiative, Canada Makes is a network of private, public, academic, and non-profit entities dedicated to promoting the adoption and development of additive manufacturing in Canada. For more information on Canada Makes, please visit www.canadamakes.ca

Media contact:
Frank Defalco at frank.defalco@cme-mec.ca

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